U.S. patent application number 11/706007 was filed with the patent office on 2007-08-30 for system and method for processing material panels.
Invention is credited to Paul Block, Michael Lydick.
Application Number | 20070199493 11/706007 |
Document ID | / |
Family ID | 38442817 |
Filed Date | 2007-08-30 |
United States Patent
Application |
20070199493 |
Kind Code |
A1 |
Block; Paul ; et
al. |
August 30, 2007 |
System and method for processing material panels
Abstract
A system for processing a material panel is provided including a
table supported by a plurality of legs, the table having at least
one linear edge. A sewing machine is provided functionally
connected to the table at the at least one linear edge. An elongate
track is provided mounted along the at least one linear edge. At
least one sensor movable along said track is provided for measuring
at least a length of the material panel.
Inventors: |
Block; Paul; (Nesconset,
NY) ; Lydick; Michael; (East Bend, NC) |
Correspondence
Address: |
KEUSEY, TUTUNJIAN & BITETTO, P.C.
20 CROSSWAYS PARK NORTH, SUITE 210
WOODBURY
NY
11797
US
|
Family ID: |
38442817 |
Appl. No.: |
11/706007 |
Filed: |
February 14, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60777306 |
Feb 28, 2006 |
|
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Current U.S.
Class: |
112/475.04 |
Current CPC
Class: |
D05B 11/005 20130101;
D05B 35/102 20130101 |
Class at
Publication: |
112/475.04 |
International
Class: |
D05B 1/00 20060101
D05B001/00 |
Claims
1. A system for processing a material panel comprising: a table
supported by a plurality of legs, the table having at least one
linear edge; a sewing machine functionally connected to the table
at said at least one linear edge; an elongate track mounted along
said at least one linear edge; and at least one sensor movable
along said track for measuring at least a length of the material
panel.
2. The system of claim 1, further comprising an operator interface
operably connected to at least the sewing machine.
3. The system of claim 2, wherein the operator interface is
configured for inputting of desired finished length and width data
for the material panel.
3. The system of claim 1, wherein the legs comprise adjustable legs
configured to be independently adjustable in height.
4. The system of claim 1, further comprising a movable material
edge guide mounted adjacent to the sewing machine along said at
least one linear edge.
5. The system of claim 1, further comprising a means for moving the
sewing machine relative to said at least one linear edge, based on
measurement feedback from said at least one sensor.
6. A system for processing a material panel comprising: a table
supported by a plurality of legs, the table having at least one
linear edge; a sewing machine functionally connected to the table
at said at least one linear edge; an elongate track mounted along
said at least one linear edge; and a plurality of sensors mounted
at predetermined locations along the track, for providing
measurement feedback of at least one edge of the material
panel.
7. The system of claim 6, further comprising an operator interface
operably connected to at least the sewing machine.
8. The system of claim 6, further comprising a movable material
edge guide mounted adjacent to the sewing machine along said at
least one linear edge.
9. A system for processing a material panel comprising: a table
supported by a plurality of legs, the table having at least one
linear edge; a sewing machine functionally connected to the table
at said at least one linear edge; an elongate track mounted along
said at least one linear edge; and an operator interface operably
connected to at least the sewing machine and configured for
inputting desired measurement data for the material panel.
10. The system of claim 9, further comprising: a movable material
edge guide assembly, mounted adjacent to the sewing machine along
said at least one linear edge.
11. The system of claim 9, wherein the legs comprise adjustable
legs configured to be independently adjustable in height.
12. A method for processing a material panel comprising the steps
of: processing at least one edge of the panel using a tension
control process, wherein the step of processing further comprises
the steps of: gripping a first end of the panel using a first
carriage; moving the first carriage using a second carriage; and
deactivating the second carriage if a tension between the first and
second carriages exceeds a predetermined force.
13. The method of claim 12, further comprising the step of
connecting the first carriage to the second carriage using a
tension device, wherein the predetermined force is determined by a
tension device.
14. The method of claim 12, further comprising the step of
incorporating human input in real-time during the step of
processing.
15. The method of claim 12, wherein the step of processing further
comprises: referencing desired panel dimensions; assessing a length
of at least a first panel edge in real-time during processing of
said panel edge; and adjusting a position of an edge guide
according to the desired panel dimensions.
16. The method of claim 15, further comprising the steps of:
pivoting the panel to orient a second consecutive edge of the panel
flush with the edge guide; and processing the second edge of the
panel using the tension control process.
17. The method of claim 16, wherein the step of pivoting further
comprises activating a pivot arm to turn the panel until a pivot
sensor is activated.
18. The method of claim 16, further comprising the step of
assessing if all edges of the material panel have been processed.
Description
[0001] The present application claims priority from U.S.
Provisional Application Ser. No. 60/777,306 entitled, "Automated
Serger Flanger," filed on Feb. 28, 2006.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates generally to sewing machinery,
and more specifically, to an overlock sewing machine and flanger
system especially for use in processing heavy duty fabrics, textile
materials and the like, such as material or fabric panels for use
in mattress construction.
[0004] 2. Description of Related Art
[0005] When preparing and quilting panels for use as, e.g., top and
bottom cover panels in mattresses, the panels are generally
initially cut with spare material in both the length and width
dimensions. This is due to the fact that the next operation after
cutting the cover panel (which leaves raw edges on all four sides)
is to sew and close the panel, e.g., with an overlock sewing
machine.
[0006] While it is desirable to leave a consistent overcut (e.g.,
typically about 1.0 inch to about 3.0 inches of extra material
overhanging each edge of the panel), quilting operators often set
up panel cutters inconsistently, leaving more or less than the
desired material overcut on the length and width dimensions of each
panel. In addition to this problem, manual sewing operators often
trim panels inconsistently, either trimming too much or not enough
material. Further, the panels, once trimmed in their length and
width dimensions, undergo some amount of shrinkage due to tension
applied in the sewing pattern, thus affecting their actual overall
length and width dimensions, often by an inch or more.
[0007] Moreover, when processing (trimming/sewing) the corners of a
panel (preferably to achieve rounded corners), sewing operators
often have great difficulty in producing consistent results in
accordance with factory-specified corner radius specifications. For
example, due to material handling issues and/or human
inconsistency, operators of serger/flanger machines often will,
e.g., begin the corner turn too early/too late, and/or not turn the
panel smoothly and consistently during the pivot, resulting in a
less than the optimal (e.g., 90 degree) arc. As such, a number of
defective panels are inevitably produced and wasted.
[0008] Typically, in fully automated machinery, processes are
performed by the machine to adhere to specific guidelines and are
carried out in accordance with specific protocol at definite times.
Consequently, the processes are often forced and a human operator
has little or no control or input during, e.g., manipulation and
sewing of a product. Machines that strictly dictate the procedures
that must be done and how quickly the operator must perform the
task, invoke a disconnected and forced work atmosphere, causing
stress to human operators and ultimately reducing finish quality of
the product. Bulky materials, such as, e.g., mattress panels, often
require fine-tuning in their positioning and orientation during
processes such as trimming and sewing. Such fine-tuning must also
be performed in real-time and is difficult, if not impossible to
achieve satisfactorily via machinery alone.
[0009] Accordingly, an efficient and effective system and method
for accurately producing consistently sized and shaped mattress
cover panels according to desired dimensions while incorporating
user input in real-time is highly desirable.
SUMMARY OF THE INVENTION
[0010] A system and method is provided for automated measurement,
adjustment and processing of material panels, e.g., mattress panels
while incorporating human user input, thus enabling production of
panels having dimensions (e.g., length/width) that consistently and
accurately correspond to pre-programmed sets of desired dimensions
while allowing a human operator to perform, e.g., real-time tactile
adjustments as needed during the sewing/cutting process.
[0011] According to one aspect, a system for processing a material
panel is provided comprising a table supported by a plurality of
legs, the table having at least one linear edge and a sewing
machine functionally connected to the table at said at least one
linear edge. An elongate track is provided mounted along the at
least one linear edge, and at least one sensor movable along said
track is provided for measuring at least a length of the material
panel.
[0012] According to another aspect, a system for processing a
material panel is provided comprising a table supported by a
plurality of legs, the table having at least one linear edge and a
sewing machine functionally connected to the table at the at least
one linear edge. An elongate track is provided mounted along the at
least one linear edge and a plurality of sensors mounted at
predetermined locations along the track are provided for providing
measurement feedback of at least one edge of the material
panel.
[0013] According to yet another aspect, a system for processing a
material panel is provided comprising a table supported by a
plurality of legs, the table having at least one linear edge and a
sewing machine functionally connected to the table at said at least
one linear edge. An elongate track is provided mounted along the at
least one linear edge and an operator interface operably connected
to at least the sewing machine is provided configured for inputting
desired measurement data for the material panel.
[0014] According to yet another aspect, a method for processing a
material panel is provided comprising the steps of processing at
least one edge of the panel using a tension control process,
wherein the step of processing further comprises the steps of
gripping a first end of the panel using a first carriage, moving
the first carriage using a second carriage, and deactivating the
second carriage if a tension between the first and second carriages
exceeds a predetermined force.
[0015] According to yet another aspect, a system for processing a
material panel is provided comprising a table supported by a
plurality of legs, the table having at least one linear edge, and
an elongate track mounted above the table along the at least one
linear edge. A pivot assembly is provided fixedly mounted at a
first end of the track and a pivot arm is provided having a first
end fixedly attached at the pivot assembly and configured for
rotational movement about said first end. A gripper assembly is
provided slidably mounted on the track, the gripper assembly
further comprising an actuator carriage and a carriage fixture
attached to said actuator carriage via a tension control
system.
[0016] According to yet another aspect, a system for processing a
mattress panel is provided comprising an elongate linear track, and
a pivot assembly fixedly mounted at a first end of the track. A
pivot arm is provided having a first end fixedly attached at the
pivot assembly and configured for rotational movement about the
first end. A gripper assembly is provided slidably mounted onto the
track, the assembly further comprising an actuator carriage and a
carriage fixture attached to the actuator carriage via a tension
control system.
[0017] These, and other aspects, features and advantages of the
present invention will be described or become apparent from the
following detailed description of the preferred embodiments, which
is to be read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] In the drawings, wherein like reference numerals denote
similar elements throughout the views:
[0019] FIG. 1 is a front perspective view of a serger flanger
system showing a gripper assembly in a forward position according
to an aspect of the present invention;
[0020] FIG. 2 is front perspective view of a serger flanger system
showing a gripper assembly in a midway position according to
another aspect of the present invention;
[0021] FIG. 3 is front perspective view of a serger flanger system
showing a gripper assembly in a rear position according to another
aspect of the present invention;
[0022] FIG. 4 is front perspective view of a serger flanger system
depicting a pivot arm in a partially deployed position according to
another aspect of the present invention;
[0023] FIG. 5 is front perspective view of a serger flanger system
depicting a pivot arm in a fully deployed position according to
another aspect of the present invention;
[0024] FIG. 6 is a right side perspective view of the serger
flanger system of FIG. 3 according to another aspect of the present
invention;
[0025] FIG. 7 is an enlarged front perspective view of a gripper
assembly as shown in area "A" of FIG. 3 according to one embodiment
of the present invention;
[0026] FIG. 8 is an enlarged front perspective view of a pivot
assembly as shown in area "B" of FIG. 3 according to an aspect of
the present invention;
[0027] FIG. 9 is enlarged view of section "C" of FIG. 6 depicting a
retracted edge guide according to an aspect of the present
invention;
[0028] FIG. 10 is enlarged view of section "C" of FIG. 6 depicting
an extended edge guide according to an aspect of the present
invention;
[0029] FIG. 11 is a top schematic view of a serger flanger system
including a loaded panel 1101 according to an aspect of the present
invention;
[0030] FIG. 12 is a top schematic view of a serger flanger system
with the panel 1101 positioned for commencement of a pivot cycle
according to an aspect of the present invention;
[0031] FIG. 13 a top schematic view of a serger flanger system
including panel 1101 upon completion of the pivot cycle according
to an aspect of the present invention;
[0032] FIG. 14 is a side view of an actuator assembly showing a
gripper assembly "D" according to another embodiment of the present
invention;
[0033] FIG. 15A is an enlarged side view of the gripper assembly of
section "D" of FIG. 14;
[0034] FIG. 15B is a top view of the gripper assembly of FIG.
15A;
[0035] FIG. 15C is a right side view of the gripper assembly of
FIG. 15A;
[0036] FIG. 16 is a flow chart depicting an exemplary method of
processing a material panel according to one aspect of the present
invention;
[0037] FIG. 17 is a flow chart depicting exemplary method steps of
a tension control process according to one aspect of the present
invention; and
[0038] FIG. 18 is a flow chart depicting exemplary method steps of
a measurement system according to one aspect of the present
invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0039] According to one aspect of the present invention, a system
and method is provided for automated, real-time measurement,
adjustment and processing of material panels, e.g., fabric panels
such as mattress panels, while incorporating human user input, thus
enabling production of panels having dimensions (e.g.,
length/width) that consistently and accurately correspond to
pre-programmed sets of desired dimensions while allowing a human
operator to perform, e.g., real-time tactile adjustments as needed
during the measuring/sewing/cutting, etc. process. A system and
method according to the present invention automatically stops and
locks each panel at correct pre-pivot locations and turns each
corner at precisely the desired amount (e.g., rectangular panels
are preferably pivoted at a 90 degree arc to process each
side/edge). However, while automatic control of the pivoting
process is provided, a system according to an aspect of the present
invention also accords the human operator a degree of control and
influence over pivoting/sewing maneuvers and maintains the material
in a tension-free, relaxed state at all times during processing. An
automated measuring, adjusting and pivoting process which
simultaneously takes into account real-time human input according
to one aspect of the present principles advantageously minimizes
handler/operator error and prevents waste due to, e.g., defective
panels while preserving the operator's ability to make tactile
adjustments to the material comfortably in real-time.
[0040] Note that placement and orientation of the elements as shown
in the Figures is for exemplary and illustrative purposes only, and
alternate locations of any of the elements may be contemplated.
Further, a system and method according to the present principles
may be applied to any type of material panels, not necessarily
mattress panels.
[0041] Referring now to the Figures, FIGS. 1-3 depict front
perspective views of a serger flanger system 100 showing a gripper
assembly 101 in forward, midway and rear positions, respectively,
according to aspects of the present invention. The system 100 is
comprised of a table 103 supported by a plurality of legs 105, each
of which is preferably independently adjustable at least in height,
so as to enable positioning of the table 103 at various heights
and/or dispose the table at various angles or inclines. The table
may be configured for manual or automatic height adjustment (e.g.,
via a pneumatic system). For example, legs 105 may be adjusted to
be higher on one side of the table 103 than the other, thus causing
table 103 to be sloped at an angle. This permits a material panel
1101 (e.g., see FIGS. 11-13) loaded onto the table to itself be
tilted during processing and due to gravity, have one edge rest
more heavily on a guide plate (e.g., an edge guide 901, described
further below with reference to FIGS. 9-13) in front of the sewing
machine during sewing. For example, preferred operational settings
may comprise wherein the table 103 is provided at angles ranging
from, e.g., about 5 degrees to about 15 degrees, and most
preferably, comprises about 10 degrees. Such angulation of the
table surface advantageously facilitates `processing` (e.g.,
procedures such as measuring, sewing, cutting, etc.) of the
material panels during operation.
[0042] The height of table 103 in relation to the ground may also
be adjusted to custom fit a human operator, thus decreasing strain
during operation and improving ergonomics. The table 103 may
comprise, e.g., an `air` table, including a plurality of openings
104 at least on a top surface thereon through which air is caused
to be emitted, therefore reducing friction on materials placed on a
top surface.
[0043] The gripper assembly 101 is positioned above the table 103
by way of an elongate linear actuator or track 107 which is mounted
longitudinally along one side of the table 103. The gripper
assembly 101 is slidably mounted onto the actuator 107, and
configured to be freely slidable along the length of the track 107.
For example, in a fully forward position, the gripper assembly 101
is positioned closest to a pivot assembly 109, with midway and rear
positions having the gripper assembly 101 positioned further away
from the pivot assembly 109. The pivot assembly 109 is preferably
fixed to one end of the linear track 107 adjacent to a sewing
machine 111 and is the location at which a human operator is
typically positioned during processing of a panel and operation of
the system 100.
[0044] FIGS. 4 and 5 are front perspective views of a serger
flanger system depicting a pivot arm 405 in a partially deployed
position (e.g., about 45 degrees) and a fully deployed position
(e.g., about 90 degrees), respectively, according to aspects of the
present invention. The pivot arm 405 is comprised of an elongate
plate generally `connected` to, e.g., at least a base of the pivot
assembly 109 at one end and configured for rotational movement
about said connected end. The pivot arm 405 may be `connected` to
the pivot assembly 109, e.g., in the sense that they may share,
e.g., a common base plate, however, not necessarily a common
centerpoint. That is, the pivot arm 405 may be `connected` to the
pivot assembly 109 yet does not have to move a mattress panel in an
arc precisely corresponding to a center of the pivot assembly 109.
In the case of a rectangular panel, the pivot arm 405 is typically
configured to move in, e.g., a substantially 90 degree arc. Note
however, that the range of movement of the pivot arm 405 may be
adjustable as desired so as to comprise less than or greater than
90 degrees.
[0045] When a panel 1101 (e.g., mattress panel) is properly
positioned on the table 103 for processing (measuring, sewing,
cutting, etc.), one side/edge of the panel is placed adjacent to
the pivot arm 405 (e.g., as shown in FIG. 11). During processing,
when the panel is ready to be turned, the pivot arm 405 is deployed
to turn the panel (e.g., about 90 degrees), thus providing a
mechanical assist in handling the weight of the panel during
pivoting, such that the operator does not have to pull the full
weight of the material around the turn as the panel's corner edge
is processed/sewn. Advantageously, this allows the operator to
concentrate fully on tailoring the finish of the panel corner edge,
and relieves the operator from the stress of moving the material
entirely by hand at every turn. Further, the panel material is
prevented from being unduly stretched, distorted or damaged by
manual handling, tugging and pulling.
[0046] FIG. 6 is a right side perspective view of a serger flanger
system according to an aspect of the present invention. The pivot
assembly shown in area "B" includes a sewing machine 111 and a
support 601 for an operator interface 801 (see FIG. 8). An
adjustable edge guide 607 is provided slidably attached to guide
shaft 603. The edge guide 607 may be adjustable and caused to be
positioned at various increments along guide shaft 603 up to a
maximum extension as determined by, e.g., industry standards (e.g.,
about 4 inches), so as to effectuate the desired amount of material
length to be cut on each panel side (described further below with
reference to FIGS. 9-10). Note that this amount may be changed as
desired in accordance with, e.g., user input. Ball screw 605 is
functionally connected to a motor (not shown) which receives data
from a computer program in the interface 801 and drives the edge
guide 607 along the guide shaft 603 via, e.g., rotational
translation to generate accurate linear movements of the guide
607.
[0047] FIG. 7 is an enlarged front perspective view of the gripper
assembly as shown in area "A" of FIG. 3 according to one embodiment
of the present invention. According to one embodiment, a gripper
assembly 101 comprises an actuator carriage 701 which is preferably
motorized and includes a tension control system comprised of an air
spring device 703, tension control sensor 705 and a sensor
activator 707. The actuator carriage 701 with the tension control
system is operably connected to a carriage plate or fixture 721 and
configured to drive the fixture 721 along the track 107 in a
controlled fashion with minimal tension or stress being exerted on
the material (e.g., mattress panel) being held by the carriage
plate 721.
[0048] The carriage plate 721 is slidably attached to the track 107
(e.g., via carriage wheels 729) and further includes clamp actuator
cylinders 709, 723, a guide shaft 711 and a clamp plate 713 and
clamp pad 717 operably mounted thereon. In one embodiment, the
track 107 may include a sensor strip 727, configured to work
together with at least one sensor 725 (e.g., mounted behind
carriage plate 721) to assist in conveying distance information
(and hence measuring panel edge lengths) as the carriage plate
moves along the track 107, e.g., described further below with
reference to FIGS. 11-13. In one embodiment, sensor 725 may
comprise, e.g., at least one magnetic sensor and strip 727 may
comprise a magnetic sensor strip. However, alternate sensor
means/systems for assessing distance/measurement information of
material panels may be contemplated, e.g., using at least one
movable sensor (e.g., configured to be movable along track 107)
and/or a plurality of discrete sensors located at predetermined
positions along track 107. Sensor systems comprising e.g., linear
and/or rotary encoders, ultrasonic sensor systems, multiple fixed
reflective sensors arranged at predetermined locations along the
track 107, etc. may be contemplated.
[0049] A material edge sensor 719 (e.g., a photocell/photoeye
sensor) is provided mounted on an upper plate 720, and a
corresponding sensor reflector 715 is provided on the clamp plate
713, both configured to detect an edge of the panel. During
operation according to one embodiment, when an edge of material is
detected via the material sensor 719 and reflector 715, the
actuator carriage 701 is caused to stop moving and the clamp
actuator cylinders 709, 723 are deployed, lowering the clamp pad
717 until it has successfully clamped the material onto the lower
clamp plate 713. Advantageously, a gripper assembly incorporating a
photocell edge detection system according to the present invention
ensures that an leading edge of the panel is fully and definitely
captured for each run, despite any errors that might have
previously occurred (e.g., operator error during turning). That is,
the clamp pad 717 is configured to close down only when the sensor
719 has been activated.
[0050] Once the clamp pad and plate 717, 713 have engaged the
material, the actuator carriage 701 is energized, such that the
carriage 701 is caused to be moved in a backwards direction (e.g.,
depicted by arrow 102 in FIG. 1) away from the sewing machine 111.
The carriage 701 continues to move until the tension between it and
the carriage plate 721 exceeds a force of the air spring 703. When
this force is exceeded, the actuator carriage 701 begins to
separate from the carriage plate 721 until the tension control
sensor 705 is activated by the sensor activator 707. That is,
according to one embodiment, the sensor 705 may be activated while
the activator 707 is located underneath it. When the actuator
carriage 701 and the carriage plate 721 become separated (e.g.,
indicating that the carriage plate 721 is moving at a slower rate
than the actuator carriage 701) the activator 707 will no longer be
located beneath the sensor 705. This results in a loss of signal
which accordingly causes the actuator carriage 701 to be turned off
and the carriage plate 721 to be stopped. Advantageously, a tension
control process according to an aspect of the present invention
ensures that the material to be processed is not caused to be
subject to undesirable tension. "Undesirable tension" is defined as
tension which elongates and/or stretches the fabric/material being
processed. Stretching the material would distort the panel
dimensions, and significantly and negatively affect the tolerance
of the cut width of the trim material and accordingly lead to
misshapen or otherwise defective panels with inaccurate
dimensions.
[0051] FIG. 8 is an enlarged front perspective view of a pivot
assembly 109 as shown in area "B" of FIG. 3 according to an aspect
of the present invention. The pivot assembly 109 includes a pivot
actuator 803 operably connected to activate a pivot clamp 807, and
a pivot sensor 805 and a pivot sensor reflector 809 for triggering
deployment and operation of the pivot actuator 803. For example,
the pivot sensor 805 may be oriented at a first location and the
pivot sensor reflector 809 at a second location, and deployment of
the sensor 805 may be caused by movement of the reflector 809 from
the second location to the first location.
[0052] A control interface 801 preferably including a screen
display is provided operably connected to the serger system 100
(e.g., at least the sewing machine 111, the pivot assembly 109, the
gripper assembly 101 and pivot arm 405) and configured to enable
user input of settings, dimensions, measurements, etc. for
material/mattress panel processing. For example, the operator
interface 801 may be configured for a user to input at least
desired lengths and widths for finished material panels. The
interface 801 may comprise a computer having stored thereon
software including algorithms for, e.g., measuring, cutting, sewing
processes, etc.
[0053] Advantageously, a pivot system according to the present
invention comprises a `passive` pivot de-coupled from any drive
source, thus enabling the operator to turn and manipulate a panel
corner at his/her own speed. When the pivot assembly engages the
panel corner, it is driven rotationally by the material itself as
it is turned by the force imposed by the pivot arm 405. The pivot
assembly provides a guide for the overall geometry of the movement,
but the operator is allowed freedom to determine, e.g., how fast or
slow the operation is to be performed, and can make real-time
adjustments during corner processing (e.g., smooth out the fabric
during sewing, pick up an edge and pull it tight during the turn,
etc.).
[0054] Furthermore, the pivot actuator 803 is configured to be
adjustable relative to the other components of the pivot assembly.
That is, the pivot cylinder actuator 803 is configured to be
movable, e.g., towards and away from the sewing machine 111 to,
e.g., increase/decrease the pivot radius of the panel corners, thus
enabling the creation of panels having varied radius sizes. Such
adjustability may be provided via, e.g., use of fastening members
to secure the pivot actuator which may be loosened or tightened as
desired, and/or an automatic adjustment system including an
additional actuator connected to the pivot actuator 803 which may
be controlled through the operator interface 801.
[0055] The pivot sensor reflector 809 is operably connected to the
pivot clamp 807, such that rotation of the pivot clamp 807 during
turning of a material panel 1101 causes the pivot sensor reflector
809 to turn with it in a corresponding arc. That is, in operation,
as the operator sews along one edge of a panel, the carriages 701,
721 move backwards in direction 102 with the material's leading
edge grasped in clamp 717 until the trailing edge of the panel
reaches a pivot actuation reflector 811, which works in conjunction
with (e.g., is in functional communication with) a pivot actuation
sensor 813. That is, e.g., the sensor 813 may be configured to
transmit a polarized light beam to reflector 811, which may then be
reflected back to the sensor 813. In the event a state of the light
path is altered (e.g., the light path is reflected or interrupted
due to, e.g., a panel edge) the sensor 813 may transmit a signal to
the operator interface 801. The carriage 701 is stopped and once
the panel 1101 stops moving, the clamp actuator cylinder 709, 723
disengages and lifts upwards, releasing the material 1101. Once the
material is free of its grasp, the linear actuator 107 is energized
again, moving the actuator carriage 701 and carriage plate 721 back
to their rear-most position farthest from the sewing machine (e.g.,
as shown in FIG. 3) in a `waiting` position, free and clear of the
material.
[0056] At this point, the pivot actuator cylinder 803 is energized,
driving the pivot clamp 807 onto the top of the material below.
Preferably, the position of the pivot clamp 807 is preset to a
desired amount (e.g., 2.0'', 2.5'', 3.0'', etc.) at which the
radius of the corner is to be configured. As a panel is rotated,
each corner is accordingly trimmed and sewed by the sewing machine
111. Rotation of the panel is facilitated by the pivot arm 405 as
discussed above, and as the pivot clamp 807 turns with the
material, the pivot sensor reflector 809 turns with it, moving in a
radial direction towards the pivot sensor 805.
[0057] When the reflector 809 is directly beneath the pivot sensor
805, this indicates that the panel has been rotated the precise
desired amount (e.g., about 90 degrees for a rectangular panel,
although this angular dimension may be adjusted as discussed
above). For example, the pivot sensor 805 may be configured to
direct polarized light in a downwards direction that can only be
reflected by the reflector 809. The arrangement and use of the
pivot sensor/reflector system according to an aspect of the present
invention ensures consistent rotation of the panel and accordingly,
consistent processing (cutting and sewing) of the panel
corners.
[0058] Once the panel has been rotated the desired amount (e.g.,
when the pivot sensor reflector 809 has reached the pivot sensor
805), the pivot actuator cylinder 803 is de-energized and the pivot
clamp 807 is retracted upwards, freeing the material. The pivot arm
405 is caused to swing back to its original, retracted `home`
position (e.g., as shown in FIGS. 1-3).
[0059] FIGS. 9 and 10 are enlarged views of section "C" of FIG. 6
depicting retracted and extended edge guides, respectively,
according to aspects of the present invention, and are heretofore
described in conjunction with FIGS. 11-13, which schematically
depict a panel 1101 at various phases of processing by a system
according to the present invention.
[0060] FIG. 9 shows edge guide 901 retracted in a `home` position,
e.g., flush to table edge 905. The edge guide 901 is configured to
be adjacent to a panel edge 1102 when in the home position. The
edge guide 901 may be set in this position when e.g., a nominal
edge trim of a panel is desired (e.g., up to about 1/2''). FIG. 10
shows edge guide 901 in an extended position, extended from table
edge 905 along guide shaft 603 via ballscrew 605 a predetermined
distance from table edge 905 in order to effectuate a desired trim
amount of a panel edge. The edge guide 901 may be
extended/retracted any desired distance in a direction Z from the
table edge 905, e.g., preferably to a maximum extension of about 4
inches, and is operably connected to the user interface 801.
Direction Z lies in a plane which is preferably substantially
parallel to a plane of a surface of table 103. Edge guide 901 may
be automatically adjustable in accordance with desired panel edge
trim amounts which may be input to the interface 801 by an
operator.
[0061] In an alternate embodiment, the edge guide 901 may be
provided fixedly attached to table edge 905 and a sewing head of
the sewing machine 111 may be configured to be movable and
adjustable relative to such fixed edge guide based on measurement
feedback (e.g., from panel length measurement sensors) with regards
to dimensions of the material panel.
[0062] Material slow-down sensor 903 assists, e.g., in slowing the
sewing machine 111 down from a maximum speed to a slower speed as
the trailing edge of a panel approaches the sewing machine 111.
This allows the sewing machine 111 to stop accurately on an edge of
the panel and prevents over-traveling. Preferably, the material
slow-down sensor 903 is oriented on the table 103 at least at a
distance `Y` from pivot actuation reflector 811 such that when the
slow-down sensor 903 is triggered, the sewing machine 111 has
sufficient time to make at least about a 20-25% reduction in its
top sewing speed prior to when the edge of the panel reaches the
reflector 811. Advantageously, once the panel has attained about a
20-25% reduction in processing speed prior to reaching reflector
811, the panel can be successfully and accurately stopped at the
precise desired location (e.g., at reflector 811). An exemplary
distance `Y` may comprise at least about 6 inches. Furthermore,
location of the slow-down sensor 903 on table 103 is preferably at
least at a distance `X` from the table edge 905, so as to be out of
range of unintentional human interference from an operator. An
exemplary distance `Y` may comprise at least about 24 inches.
[0063] In addition, the material slow-down sensor 903 may be used
to determine the length and width of the panel, as described below
e.g., with reference to FIGS. 11-13.
[0064] A panel 1101 loaded onto table 103 includes a leading edge
1103 which is grasped by the gripper assembly 101, a side edge 1102
positioned flush against edge guide 901 which comprises the edge
being processed (e.g., cut/sewn), and a trailing edge 1105 which is
the next edge of panel 1101 to be processed after processing of the
side edge 1102 is completed.
[0065] An exemplary system and method for automatically determining
panel length according to one aspect of the present principles will
now be described. A distance 1113 is measured via the magnetic
sensor 725 located on gripper assembly 101, relative to the pivot
center 1107. That is, when the gripper assembly 101 is fully
forward (e.g., closest to the sewing machine 111) the distance from
the gripper 101 to the pivot center 1107 is a fixed and known value
(e.g., X inches). As the gripper assembly 101 moves backwards in
direction 1117, the additional distance is added to the fixed value
X to produce value 1113.
[0066] A distance 1115 (e.g., the distance from the material
slow-down sensor 1109 to pivot center 1107) also typically
comprises a fixed and known (predetermined) value. When the
trailing edge 1105 of the panel 1101 triggers the sensor 1109, the
system (e.g., via user interface computer 101) adds together the
distances 1113 and 1115. Accordingly, a full length of the panel
side 1102 is determined.
[0067] An exemplary trimming and pivoting system and method
according to one aspect of the present principles will now be
described. Referencing the desired panel dimensions entered into
the user interface, the system permits the operator to sew until
the desired length of the panel side has been sewn, and stops at
the precise location required to have the side sewn the desired
length after the pivot operation. For example, an operator desires
the panel to be 80.5'' in length. The system (e.g., via the sensor)
determines that the length of the panel is 83.25'' (length of 1113
plus 1115). Therefore, a 2.75'' scrap 1203 (cross-hatched area)
will need to be trimmed off on the next panel side 1105.
[0068] To accomplish this, the system moves the edge guide 901
2.25'' away from the table edge 1205. The gripper assembly 101,
grasping the leading edge 1103 of the panel, moves the panel in
direction 117 until the trailing edge 1105 reaches the pivot center
1107 (thus activating the pivot actuation sensor as discussed
above). The gripper assembly 101 releases the panel and goes into
the docked or `waiting` position (e.g., see FIG. 13) while the
pivot assembly pivots the panel (here, about 90 degrees) in
direction of arrow 1301. Once the panel is pivoted, the panel edge
to be trimmed is positioned flush against an extended edge guide
901. Thus the trim edge 1201 is caused to line up with trim knife
1001 of the sewing machine, which cuts along edge 1201 thereby
trimming off cross-hatched area 1203.
[0069] FIG. 14 is a side view of an actuator assembly showing a
gripper assembly in area "D" according to another embodiment of the
present invention, and FIGS. 15A-C are enlarged front, top and
right side views, respectively, of the gripper assembly in area "D"
of FIG. 14.
[0070] According to an alternate embodiment, a gripper assembly
1501 comprises an actuator carriage 1503 which is preferably
motorized and includes a tension control system. In this
embodiment, the tension control system is comprised of a tension
coil device 1505, tension control sensor 1507 mounted on the
actuator carriage 1503 and a sensor activator 1509 mounted onto the
carriage plate 1511. The coil device 1505 is comprised of a length
of material having tensile force (e.g., a coiled metal material),
with a first end secured to base 1506 mounted on the carriage plate
1511 and a second end to reel 1504 mounted on the actuator carriage
1503. Thus, the actuator carriage 1503 with the tension control
system is operably connected to the carriage plate 1511 and
configured to drive the plate 1511 along the track 1513 in a
controlled fashion with minimal tension or stress being exerted on
the material (e.g., mattress panel) being held by the carriage
plate 1511.
[0071] The carriage plate 1511 is slidably attached to the track
1513 and further includes clamp actuator cylinders 1515, 1517, a
guide shaft 1519 and a clamp plate 1523 and clamp pad 1527 operably
mounted thereon. In one embodiment, the track 1513 may include a
sensor strip 1514, configured to work together with at least one
sensor (not shown--e.g., may be mounted behind carriage plate 1511)
to assist in measuring panel edge lengths, described above, e.g.,
with reference to FIGS. 11-13. In one embodiment, the sensor may
comprise, e.g., at least one magnetic sensor and strip 1514 may
comprise a magnetic sensor strip. However, alternate sensor means
for assessing distance information may be contemplated, such as
rotary encoders, ultrasonic sensor systems, multiple fixed
reflective sensors arranged at discrete locations along the track
1513, etc.
[0072] A material edge sensor 1529 (e.g., a photocell/photoeye
sensor) is provided mounted on an upper plate 1521, and a
corresponding sensor reflector 1525 is provided on the clamp plate
1523. During operation according to one embodiment, when an edge of
material is detected via the material sensor and reflector 1529,
1525, the actuator carriage 1503 is caused to stop moving and the
clamp actuator cylinders 1515, 1517 are deployed, lowering the
clamp pad 1527 until it has successfully clamped the material onto
the lower clamp plate 1523.
[0073] Once the clamp pad and plate 1527, 1523 have engaged the
material, the actuator carriage 1503 is energized, such that the
carriage 1503 is caused to be moved in a backwards direction 1530
(e.g., away from the sewing machine 111). The carriage 1503
continues to move until the tension between it and the carriage
plate 1511 exceeds a force of the tension coil 1505. When this
force is exceeded, the actuator carriage 1503 begins to separate
from the carriage plate 1511 until the tension control sensor 1507
is activated by the sensor activator 1509. Advantageously, this
process ensures that the material to be processed is not caused to
be subject to undesirable tension, thus avoiding misshapen or
otherwise defective panels with inaccurate dimensions.
[0074] FIG. 16 is a flow chart depicting an exemplary method of
processing a material panel according to an aspect of the present
invention. Note that components described in the method steps may
comprise any of the components described above, and are not limited
to a single embodiment of a component. For example, the term
"gripper assembly" may include the gripper assembly shown in either
FIG. 7 or FIG. 15A.
[0075] In step 1601, when a panel is desired to be loaded, a
gripper assembly (e.g., 101) in serger flanger system according to
the present invention is preferably moved to a docked position
(e.g., as shown in FIG. 3). The operator loads a panel (e.g.,
quilted mattress panel) beneath the presser foot/material clamp of
the sewing machine and aligns the edge of the panel to the edge
guide (e.g., adjustable edge guide 901).
[0076] In step 1605, once the panel is loaded, the operator may
select a desired final trim size e.g., either by entering a value
or selecting a pre-programmed choice displayed on the touch screen
operator interface (king size bed, queen, twin, full, etc.). Once
the choice has been made, the operator may press the "START"
command on the screen to start the system.
[0077] In step 1607, the gripper assembly (actuator carriage 701,
1503 and carriage plate 721, 1511) is moved forwards, towards the
sewing machine, from its docked rear position (start-up position).
The clamp plate actuator (e.g., 7091 may also be activated, until
the lower face of the clamp plate (e.g., 715, 1523) is just above
the table top surface ( 1/16'' clearance). The actuator continues
moving the carriage assembly until the material sensor (e.g., 719,
1529) detects the leading edge of the panel. Once the edge is
detected, the carriage immediately freezes/locks in position. The
clamp actuator then engages, lowering the clamp until it has
clamped the panel material to the lower clamp plate.
[0078] Once the clamp has positively engaged the material, the
linear actuator is then energized (step 1609), such that the
actuator carriage (e.g., 701, 1503) is driven backwards away from
the sewing machine, pulling the panel under the sewing machine
which accordingly processes (trims and/or sews) the panel edge,
while employing a tension control system. FIG. 17 outlines
exemplary method steps of a tension control process according to an
aspect of the present invention. Namely, the actuator carriage
continues to move backwards (and accordingly pull the panel
backwards) until it is determined (step 1701) that the tension
between the actuator carriage and the carriage plate (e.g., 721,
1511) exceeds the force of the tension control device (e.g., 703,
1505). When this force is exceeded, the actuator carriage begins to
separate from the carriage plate until the tension control sensor
is activated by the sensor activator (e.g., a steel plate actuating
a magnetic proximity detector sensor), at which point the actuator
carriage is stopped (step 1705). If at step 1701 the tension is not
exceeded, the process continues to drive the actuator carriage
backwards (step 1703) and the process goes back to step 1701.
[0079] At step 1707, it is determined if the sensor is deactivated.
If no, the process goes back to step 1705. If yes, the actuator
carriage is re-energized and moved backwards (step 1709) and the
process loops back to step 1701. A tension control system and
method according to the present principles is preferably employed
at all times during which each panel edge is being handled and
processed by a serger flanger system according to the present
invention. Advantageously, a tension control system and method
according to an aspect of the present principles ensures that the
gripper assembly can never apply any excess tension to the product
being sewn.
[0080] As the operator sews along one straight edge of the panel,
the gripper assembly moves backwards with the panel's leading edge
in its grasp. In step 1611, it is determined whether a trailing
edge of the panel has passed/reached the material slow-down sensor
(e.g., 903). If no, the process goes back to step 1609. If yes, it
is determined in step 1613 whether a panel dimension measurement
system has been activated. If no, in step 1615 it is determined
whether the trailing edge has reached the pivot actuation sensor
(e.g., 811). If yes, the process proceeds to step 1801, described
further below.
[0081] If the trailing edge of the panel has reached the pivot
actuation sensor, the leading edge of the panel is disengaged, the
gripper assembly is moved to the docked position and the pivot
clamp (e.g., 807) is caused to engage the panel edge corner (step
1617). That is, movement of the panel is stopped and the clamp
actuator cylinder disengages and lifts upwards, releasing the panel
from its grasp. When the panel is free, the main linear actuator is
energized again, bringing the gripper assembly back to its rear
most position (farthest from the sewing machine), free and clear of
the panel. At this point, the pivot actuator cylinder (e.g., 803)
is energized, driving the pivot clamp down into the top of the
panel material below. The pivot clamp position may be preset such
that the desired radius (e.g., 2.0'', 2.5'', 3.0'') is guaranteed
as the panel is rotated and processed (e.g., trimmed and/or sewn by
the sewing machine).
[0082] When the pivot clamp is fully depressed, the system waits
for the operator to depress the sewing machine treadle pedal. In
step 1619 the operator deploys the treadle pedal to commence
processing of the panel corner). When the pedal is depressed, the
machine begins to sew. Because the pivot clamp is engaged, the
panel material is forced to turn radially, centered about the pivot
clamp. As the pivot clamp turns with the material, the pivot sensor
reflector (e.g., 809) turns with it, moving radially towards the
pivot sensor (e.g., 805). As this is occurring, the pivot plate is
sweeping the panel in an arc (step 1621), preferably e.g., about 90
degrees, and handles the full weight of the panel, such that the
operator is not required to pull the fabric around the table as the
panel corner edge is sewn. Again, this allows the operator to
concentrate fully on the tailored finish of the corner, as well as
relieve the stress of moving the material by hand.
[0083] This portion of the cycle continues until the pivot sensor
reflector is directly beneath the pivot sensor, thus activating the
pivot sensor (step 1623). For example, this position may be preset
to correspond to a precise rotation of exactly 90 degrees (though
this angular dimension can be adjusted to a slightly larger or
slightly smaller dimension as desired), and ensures that the panel
is consistently rotated the desired amount at every corner of the
panel being processed.
[0084] Once the panel has rotated the full desired amount, the
pivot actuator cylinder is de-energized, and the pivot clamp is
retracted upwards. Also, the pivot plate is caused to be retracted
backwards to its home position (step 1625). In step 1627 it is
determined whether it is time for a 3.sup.rd or 4.sup.th edge of
the panel to be processed. This determination may be made with the
computer 801, which may keep track of what number edge of a given
panel is being processed. If yes, a panel dimension measurement
system is activated (step 1631) and the process goes back to step
1607. Steps 1607, 1609, 1611 are repeated, and at step 1613, the
process proceeds to step 1801 in which any dimensions input from
the operator prior to beginning the sewing cycle are referenced.
FIG. 18 is a flow chart depicting exemplary method steps of a panel
measurement control system according to an aspect of the present
invention, and will now be described.
[0085] In step 1803 a length of the panel edge is assessed. This
may be done by computer 801, which takes note of the orientation of
the gripper assembly and knows the linear location of the gripper
assembly via its magnetic sensor (e.g., 725) during steps 1609 and
1611. For example, as the operator continues to sew, the computer
continuously and in real-time measures the length of the panel edge
being processed, comparing it to the desired dimension(s). When the
trailing edge of the panel passes the material slow-down sensor,
the panel's absolute length along that edge is known. The computer
then automatically determines how much material needs to be trimmed
off of the next panel edge, and adjusts the moveable edge guide to
accommodate the required trim (step 1805). The process returns to
step 1615. Once the next edge is sewn, at least one of the two
desired dimensions (e.g., length and width) will be realized, since
the panel will be pivoted and the next edge will be moved flush
against the edge guide which is in the modified position to
accommodate the desired trim (e.g., as shown in FIGS. 11-13). Note
that this measuring/trimming operation may occur similarly on the
4th straight side, such that the final dimension (either length or
width) will also be realized. For example, panel material may be
trimmed off the 3.sup.rd and 4.sup.th edges in the order of
processing to attain the desired panel length and width. In one
embodiment, processing of a panel having four sides/edges may
require at least five runs (i.e., at least one edge of the panel
will be run through the process twice) to process all four edges
and four corners. That is, processing of a first side may be
started halfway along its length by default (a work-in-process tag
may be sewn in at this midway start point location). When an
operator begins processing a panel, the edge guide is preferably in
a home position (not extended). When the 4.sup.th corner of the
panel is done, the 1.sup.st edge is processed until the operator
gets up to the point where the process was started. Preferably, the
operator sews an additional few inches and overlaps the start
point. Once the overlap is completed, the operator may hit the stop
command (opening all clamps).
[0086] If at step 1627, it is determined that neither a 3.sup.rd or
4.sup.th run is about to be commenced (e.g., if a 2.sup.nd or
5.sup.th run is being started) it is determined whether all the
edges have been properly processed (e.g., whether a panel having 4
edges has been subject to at least 5 runs as described in the above
paragraph). If yes, the process is done (step 1630). If no, the
process returns to step 1607. Note that during a 5.sup.th process
run, the panel measurement system (e.g., step 1631) does not have
to be activated.
[0087] Although illustrative embodiments of the present invention
have been described herein with reference to the accompanying
drawings, it is to be understood that the invention is not limited
to those precise embodiments, and that various other alterations,
modifications and improvements may be affected therein by one
skilled in the art. Such alterations, modifications and
improvements are intended to be within the scope and spirit of the
present invention. Accordingly, the foregoing description is by way
of example only and is not intended to be limiting. This invention
should be limited only by the claims and equivalents thereof.
* * * * *